ML-565/ML-580/ ML-5106 CNC LATHE BARFEEDER
INSTALLATION, OPERATION AND MAINTENANCE MANUAL Version 01.
ATS ML565/ML580/ML5106 CNC Technology manufactures the ATS ML Iron, a company located in Czech Republic. It is distributed in North America exclusively by ATS Systems. 30222 Esperanza RSM, CA. 92688 1.800.321.1833 www.ats-s.com ATS SYSTEMS INC.
manML565/580en_V1.0.
Safety Instructions Before starting the work with the barfeeder pay attention to the following instructions: With regard to continuous improving of barfeeders it is possible that the illustrations and descriptions provided in this manual can differ in details from the delivered equipment. When working with electric circuits follow the regularly updated diagrams in this manual.
Safety Instructions • • • • • • • • • • • • • • • • • • 4 Before the use the barfeeder remove all parts and tools from the barfeeder and its vicinity, in particular from the vicinity of its moving parts. If the machine has been out of service for a longer time, check the machining program, part clamping and setting of the barfeeder parameters before fully automatic operation of the lathe with the barfeeder. Do not remove or unlock safety guards during barfeeder operation.
Safety Instructions Observe labour safety principles!!! ML-565/580T/S 5
Table of Contents TABLE OF CONTENTS LIST OF FIGURES IDENTIFICATION OF INSTRUCTIONS 1 DESCRIPTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7 GENERAL DESCRIPTION APPLICATION CONCEPT TECHNICAL SPECIFICATION PROCESS DESCRIPTION INSTALLATION IDENTIFICATION AND SERIAL NUMBER 9 10 1-1 1-1 1-1 1-2 1-2 1-6 1-6 1-7 2 TRANSPORT AND UNPACKING 2-1 3 INSTALLATION 3-1 3.1 3.2 3.2.1 3.2.2 3.2.3 3.
Table of Contents 4.9.2 KEYS 4.9.2.1 Mode Keys Aut, Man, Dat 4.9.2.2 Start Key (F1) 4.9.2.3 Function Keys F1, F2, F3 and More Key 4.9.2.4 Info Key 4.9.2.5 Navigation Keys 4.9.2.6 Numeric Keys 4.9.2.7 Enter Key 4.9.2.8 Esc Key 4.9.3 STATUS BAR 4.9.4 USER LEVELS AND THEIR MEANING 4.9.4.1 Changing User Level 4.9.5 MANUAL MODE 4.9.5.1 Move to a Reference 4.9.5.2 Standard Motions of the Barfeeder 4.9.5.3 Loading Mechanism Jogging 4.9.5.4 Material Switch Calibration (S) 4.9.5.
Table of Contents 4.10.2.13 #200 – Channel Position 4.10.2.13.1 Bar Selection from the Channel Position Table 4.10.2.13.2 Channel Position Correction 4.10.2.13.3 Stopper Position Correction 4.10.2.13.4 Inserting Nonstandard Bar into the Channel Position Table 4.10.2.14 #400 – Jobs Table 4.10.3 SERVICE PARAMETERS 4.10.3.1 #000 – Mode Automat 4.10.3.1.1 Normal Automatic Mode 4.10.3.1.2 Automatic Mode Simulation 4.10.3.1.3 Test Mode 4.10.3.2 #001 – Feeding on M-Code 4.10.3.3 #002 – End of Bar Timing 4.10.3.
Table of Contents List of Figures Main Dimensions of the Barfeeder Fig. 1.1 Fig. 1.2 Nameplate Fig. 2.1 Barfeeder Lifting and Setting Fig. 3.1 Setting the Height and Side Position Fig. 3.2 Setting Kit Fig.3.3 Barfeeder Anchoring Fig. 3.4 Electrical Connection Fig. 4.1 Bar Guiding in the Spindle Insert Fig. 4.2 Bar Feeding Fig. 4.3 Magazine Angle Setting Fig. 4.4 Pusher Dismantling and Mounting Fig. 4.5 Control Panel Fig. 4.6 Keys Fig. 4.7 Status Bar Fig. 4.8 Automatic Mode Fig. 4.9 Data Mode Fig. 4.
Identification Instructions IDENTIFICATION OF INSTRUCTIONS • Important instructions are emphasized in this manual as follows: Failure to observe these instructions can result in injury of the operator. Failure to observe these instructions can result in damage to the barfeeder or the lathe. Other important instructions • 10 Parameter numbers are identified as #xxx in this manual, where xxx is the parameter number.
Chapter 1 – Description 1 DESCRIPTION 1.1 GENERAL DESCRIPTION The barfeeder ML-565/580 T/S has been designed for work with any type of CNC lathe equipped with a suitable interface. The length of the bars is limited by the length of the lathe spindle (with a clamping cylinder and clamping device). As the barfeeder does not touch any rotating part of the lathe or rotating bar, it is possible to utilize full range of operating speed of the lathe.
Chapter 1 – Description 1.3 CONCEPT The barfeeder ML-565/580 T/S is a powerful machine with a long service life and minimal maintenance required. Its operation and functions are simple which facilitates the work even to less skilled workers. The barfeeder is controlled by means of the control panel in the right part of the machine. There is an E-Stop pushbutton for emergency stop on the control panel. In the left part of the barfeeder frame there is a Q1 switch. Bars are loaded in the magazine.
Chapter 1 – Description Pusher stroke Design stroke Working stroke Maximum distance of the clamping device face from the pusher point in back position 1665 mm 1660 mm 1655 mm Technology of bar handling The bar is cantered in the lathe spindle by spindle inserts, and shifted by the pusher to a stopper in the tool head. Spindle speed Depending on lathe design and quality of spindle insert. Bar preparation No specific requirements for bar preparation.
Chapter 1 – Description Electrical equipment Power supply Power circuits Logic circuits 200/230/400 VAC, 50/60 Hz, 320 VA 200 VAC, 24 VDC 24 VDC Noise emission The values have been stated in accordance with ČSN EN ISO 4871 and basic standard ČSN EN ISO 11201.
Chapter 1 – Description Fig. 1.
Chapter 1 – Description 1.5 PROCESS DESCRIPTION ML-565/580 T/S barfeeder feeds bars into the lathe as follows: • • • • The channel takes a bar from the magazine and lifts it to the lathe spindle axis level. The flag shifts the bar into the spindle and after it returns to back limit position. The channel moves to the lower limit position and the pusher is tilted to the spindle axis.
Chapter 1 – Description 1.7 IDENTIFICATION AND SERIAL NUMBER Serial number of the barfeeder is shown on the nameplate fastened under the magazine. Fig. 1.
Chapter 1 – Description 1-8 ML-565/580 T/S
Chapter 2 – Transport and Unpacking 2 TRANSPORT AND UNPACKING Barfeeders are sealed in plastic sheet and transported on pallets or, exceptionally, in wooden boxes (see Chapter 1.4 for dimensions). They are fastened by screws to the box bottom/pallet. To eliminate any damage, the following procedure must be observed during unpackaging, otherwise the manufacture will bear no liability for any damage in unpackaging not carried out according to this procedure.
Chapter 2 – Transport and Unpacking • Put the barfeeder on the rear side of the lathe as shown in Fig. 2.1. The distance between the rear side (rear end) of the lathe spindle and front cover of the barfeeder should be as small as possible. The gap between the barfeeder cover and lathe cover must not exceed 20 mm or it is necessary to disable insertion of the hand palm between the barfeeder and the lathe. Fig. 2.1 Barfeeder Lifting and Setting In unpacking check the completeness of standard accessories.
Chapter 3 – Installation 3 INSTALLATION 3.1 PREPARATION It is appropriate for easy and quick installation that the installation and the first start-up of the barfeeder should be carried out by the manufacturer's technician or a by a person authorized by the manufacturer. It is in the user's interest to ensure presence of the barfeeder operation and maintenance staff during installation in order for them to be familiarized with the principles of the barfeeder use in collaboration with the lathe.
Chapter 3 – Installation 3.2 BARFEEDER ALIGNMENT 1. GENERAL Barfeeder alignment with regard to the lathe is the most important installation step and must be carried out as thoroughly as possible. The time spent by this process is negligible compared to possible damage to the lathe or the barfeeder in wrong alignment. Proper alignment of the barfeedeer is important for its trouble-free run. Observe prescribed distances in installation, see Fig. 2.1. 2.
Chapter 3 – Installation 6 3. GEOMETRIC ALIGNMENT WITH THE LATHE Fig. 3.
Chapter 3 – Installation a) • • • • • • b) Preparation Dismantle the pusher. Install setting jigs, see Fig.3.2. 1. Part 3.2/1 into the clamping device of the lathe. 2. Part 3.2/3 into the front grip of the pusher. 3. Part 3.2/4 into the rear grip of the pusher. Pull the string 3.2/2 through sleeves 3.2/4, 3.2/3 and 3.2/1, and secure it by knot in the part 3.2/4. Fix the flag (pusher) in the back position by screw 3.2/6. Tighten the string to approx.
Chapter 3 – Installation c) Anchoring After proper alignment, fasten the Barfeeder to the ground by means of expansion anchor screws (2 per each leg). • Drill holes according to dimensions of the delivered anchor screws. The holes must be sufficiently deep. The screws must not seat on the bottom of the hole. • Insert the screws in the holes, and tighten them properly. Fig.3.
Chapter 3 – Installation 3.3 ELECTRICAL CONNECTION • Interconnect the barfeeder and lathe interfaces. • Set the barfeeder transformer to proper supply voltage. • Install fuses F1, F2 of proper values see Chapter 5.3.2. Note: Some types of lathes use a single cable harness for both power and communication conductors, while other types use two separate harnesses. The barfeeder connection is modified accordingly. Supply Voltage Fuse F1- F2 Interface X1 Fig. 3.
Chapter 4 – Operation 4 OPERATION 4.1 4.1.1 PRIMARY PREREQUISITES PUTTING INTO OPERATION, ANCHORING, ALIGNMENT The barfeeder must be thoroughly installed according to Chapter 3. 4.1.2 SAFETY OF OPERATION Interface and safety circuits between the lathe and the barfeeder must be properly connected and checked. The manufacturer bears no responsibility for the barfeeder operation, it the barfeeder and lathe interconnection is not carried out in accordance with the interface drawing. 4.1.
Chapter 4 – Operation 4.2.2 FEEDING TO POSITION (S) In this mode the barfeeder feeds the bar to a position set in the barfeeder. In this case the stopper is not needed. At change of work piece parameters: At change of the bar diameter: Change the spindle insert. Select the correct bar, see the parameter #200 Change the length of the pusher retract position, see the parameter #101. In significant change of the bar diameter it may be also necessary to: Change the pusher size.
Chapter 4 – Operation 4.4 BAR FEEDING Bars are as a rule fed by the pusher into the lathe workspace. The lathe spindle must not turn during feeding. If the parameter #011 is set to Magazine Only, it is possible to feed the bar using e.g. the second spindle of the lathe. In this case it is possible to feed the bar without stopping the spindle. In all cases the bar must be centred by the spindle insert. Feeding to stopper Fig. 4.2 4.4.
Chapter 4 – Operation 4.5 INSTALLATION OR REPL. OF SPINDLE INSERT (AT CHANGE OF THE BAR DIAMETER) The user shall ensure appropriate spindle inserts, see Chapter 4.3. How to replace the spindle insert • Switch the barfeeder to the manual mode, and move the channel into the position where neither the channel nor the pusher will obstruct the access to the spindle. • Release the spindle insert and put it out in the direction to the barfeeder. • Push the new insert into the lathe spindle, and fix it. 4.
Chapter 4 – Operation 4.8 PUSHER Barfeeders ML-565/580 is delivered with the following pushers. T S ∅ 6 mm with fixed point Bar ∅ 6 – 15 mm option option ∅ 10 mm with fixed point 12 – 80 mm standard standard ∅ 18 mm with fixed point 30 – 80 mm option option Pusher How to replace the pusher • Release 2 fixing screws 4.4/2 in the pusher lock, and pull the pusher 4.4/1 out from the front sleeve 4.4/3. • Replace the bush 4.
Chapter 4 – Operation 4.9 BARFEEDER CONTROL All controls of the ML-565/580 barfeeder are on the control panel. Fig. 4.5 4.9.1 Control Panel E-STOP (S1) E-Stop panel is located on the top part of the HMI, and is used for the control of safety elements of the barfeeder. The HMI also contains Emergency Stop button (S1), Power On button (S10). 4.9.1.
Chapter 4 – Operation 4.9.2 KEYS Fig. 4.6 Keys 4.9.2.1 MODE KEYS AUT, MAN, DAT Key (F1) (F2) Mode Automat Manual (F3) Data Meaning It is possible to run the barfeeder in the automatic cycle. It is possible to drive the barfeeder manually using the navigation keys. It is used to set the barfeeder parameters. 4.9.2.2 (F1) START KEY The key (F1) (Start) Key is used to start the automatic cycle of the barfeeder. All axes will return/find home position prior to starting initialization cycle.
Chapter 4 – Operation 4.9.2.3 FUNCTION KEYS F1, F2, F3 AND MORE KEY Function keys F1, F2, F3 and F4 are universal keys, which meaning changes depending on current situation and is displayed by graphic symbols in the lower part of the display. If no symbol is displayed directly above the function key, the key is non-functional in given situation. The key (SHIFT) changes the meaning of the function keys 4.9.2.
Chapter 4 – Operation 4.9.3 STATUS BAR In the manual and automatic mode in the upper part of the display there is a status bar which displays information, see Fig. 4.7. MODE INTERFACE Indicator Mode END OF BAR PART COUNTER Meaning MAN Manual AUTO Proper barfeeder automatic mode of work with a bar see #000. M M-code is active. M M-code is inactive. A Barfeeder activity is allowed from the lathe. A Barfeeder activity is forbidden from the lathe. CH Clamping device is open.
Chapter 4 – Operation 4.9.4 USER LEVELS AND THEIR MEANING Level Operator Password 1397 Service 4268 Meaning Operator level is so called permanent level i.e. after the barfeeder restart just the operator level is always activated. This means that the user always has only the operator's rights following the barfeeder switching on. The Operator level is not protected by a password. The operator can right all parameters of the barfeeder.
Chapter 4 – Operation 4.9.5 MANUAL MODE Manual mode allows barfeeder motions by means of the navigation keys. This mode is also used for the move to a reference and for the calibration of the material switch (S). 4.9.5.1 MOVE TO A REFERENCE Always after the barfeeder is switched on, first it is necessary to go to M1 motor reference. The barfeeder indicates by flashing display that it does not know a reference point.
Chapter 4 – Operation 4.9.5.3 LOADING MECHANISM JOGGING In case of need it is possible to jog the loading mechanism. Use jogging at the channel motion in non-standard situations (bar jammed in the loading mechanism), when it is necessary to move the channel irrespective of its initial position or machine reference point. How to jog the loading mechanism • By pressing (MANU) key manual mode screen is available.
Chapter 4 – Operation 4.9.5.5 INDIVIDUAL MOTOR CONTROLS (ALL ML MODELS) All motors can be operated individually in MAUNAL Mode using the SHIFT key function. When the SHIFT key is pressed in MANUAL Mode, motor keys can be utilized by Function keys F1, F2 and F3. System defaults to M1 motor operation which will be flashing when the SHIFT key is pressed. The ARROW keys can still be utilized as normal LEFT/RIGHT arrows for M1 and UP/DOWN arrows for M2 and M3.
Chapter 4 – Operation 4.9.6 AUTOMATIC MODE Automatic mode is used for startup of fully automatic working cycle of the barfeeder. Fig. 4.8 Automatic Mode 4.9.6.1 INDICATOR OF BAR HANDLING METHOD In the automatic mode, an indicator of the method of bar handling by the barfeeder is displayed in the upper part of the screen; the indicator indicates the basic behavior of the barfeeder in automatic cycle depending on parameters #010 and #011.
Chapter 4 – Operation 4.9.6.3 AUTOMATIC CYCLE START • • • • • Before starting up the lathe with the barfeeder check whether the barfeeder is in it basic position (the loading mechanism in the lower limit position and the pusher in the back limit position). If not the barfeed will automatically send all motors to home position, Go to the lathe to set the machine reference and perform preparatory actions. Be sure to clamping part. Press (F1) AUTO on barfeeder to set in automatic mode.
Chapter 4 – Operation 4.9.6.6 OPENED MAGAZINE COVER Barfeeders with CE certificate are equipped with the magazine cover, which, if open, locks the barfeeder motion in the automatic cycle. If the cover is open during the automatic cycle at an illtimed moment (during bar feeding or replacement), it may cause an error of the barfeeder and stoppage of the lathe. It is recommended to replenish the magazine only with automatic cycle switched off.
Chapter 4 – Operation 4.10 BARFEEDER PARAMETERS Barfeeder operation is controlled by parameters, which are divided into the following groups: • Operator Parameters • Channel Positions • Service Parameters Operator Parameters together with bar number the channel position corresponds to are technological parameters. The values of the technological parameters can be stored as so called jobs in the Jobs Table and reloaded into the barfeeder memory, see below. 4.10.
Chapter 4 – Operation Parameter selection by listing Use ENTER key. keys to select Operator or Service Parameters and confirm by pressing the Now you can scroll through the relevant parameter group using SELECT key. Direct selection of the parameter Use the arrow keys to select the direct selection field. Enter the parameter number using the numeric key pad and confirm it by pressing the key. 4.10.1.2 PARAMETER TYPES AND THEIR SETTING 4.10.1.2.
Chapter 4 – Operation 4.10.1.2.3 CHANNEL POSITION PARAMETER Channel Position parameter is a special parameter that set the channel position according to bar diameter. This is parameter #200. This parameter can be set automatically or manually as needed. This option is changed in Service parameters. 4.10.1.2.4 PARAMETERS OF OTHER TYPE Parameters of other type are other nonlinear numeric parameters #300 to #399.
Chapter 4 – Operation 4.10.2 OPERATOR PARAMETERS Operator parameter setting is directly dependent on the part production technology in the lathe. Material to square up the new bar #100.... End of Bar #101.... Pusher Retract Position #102.... Collet Face Position #105.... First Feeding Length #106.... Second Feeding Length #107.... New Bar Face Position (SS2300S) #110.... Pusher in Stopper Function (SS2300S) Fig. 4.10 4.10.
Chapter 4 – Operation 4.10.2.1 #100 – END OF BAR Using the parameter #100 the barfeeder checks the bar length in the lathe and decides whether the bar is or is not sufficiently long to manufacture a part. H...... part length with squarring allowance I ....... cut-off tool length J ...... safety zone (is not a part of the parameter #100) K...... minimum clamping length #100 = H + I + K Fig. 4.
Chapter 4 – Operation 4.10.2.2 #101 – PUSHER RETRACT POSITION By appropriate setting of the parameter #101 it is possible to reduce the bar feeding time. In forward motion the pusher sags by effect of its own weight. Consequently, it touches the spindle insert and the rotating spindle could damage it. Parameter #101 sets such motion of the pusher from the back position, at which the pusher cannot yet touch the spindle insert. If the parameter #101 > 0 (e.g.
Chapter 4 – Operation 4.10.2.5 #105, #106 – FEEDING LENGTH Parameters #105 and #106 set the length, by which the barfeeder will move the bar in feeding to Position (#010). The feeding length is also used in case when the barfeeder works in Magazine Mode (#011), irrespective of the value of the parameter #010. The barfeeder differs between First Feeding Length (#106) and Second Feeding Length (#107), which alternate as follows depending on the values entered in them.
Chapter 4 – Operation 4.10.2.6 #107 – NEW BAR FACE POSITION (S) Parameter #107 sets for the length, by which the new bar will be moved in front of the clamping device in the Position mode (#010). If you want to move the new bar 27 mm in front of the face of the clamping device, enter the value 27 mm in the parameter #107. 4.10.2.7 #011 – MACHINE WORK MODE Parameter #011 states the basic mode of the barfeeder operation.
Chapter 4 – Operation Part Stop (S) In the Part Stop the barfeeder is used as a fixed mechanical stop in the lathe spindle. In this case the barfeeder moves the pusher to the position saved in the parameter #110 when the clamping device opens. It remains in the position until the clamping device is closed. As soon as the clamping device is closed, the barfeeder returns back (to the position saved in the parameter #101).
Chapter 4 – Operation 4.10.2.9 #102 – COLLET FACE POSITION Parameter #102 sets the distance of the clamping device face from the barfeeder (from the end of the pusher in the back position). In setting this parameter it is necessary to observe the following procedure, which ensures correct setting of clearances, and thus correct setting of the parameter #102.
Chapter 4 – Operation 4.10.2.11 #003 – END OF BAR M-CODE (EOB M-CODE) Parameter #003 defines the barfeeder behaviour in situation, when the clamping device is closed and the lathe sends the M-code. If the lathe sends the M-code at the clamping device closed, the M-code is not understood as a feed command, but as an end of bar test. This M-code is called EOB M-code.
Chapter 4 – Operation 4.10.2.11.1 SPECIAL EOB M-CODE CASE The EOB M-code also means the M-code with the clamping device open, in the following situations. #001 ON OFF Description If the barfeeder feeds on M-code (#001=ON), then the first M-code after the clamping device opening is the M-code initiating the feeding. If the lathe sends other M-code after the sign-off of the first M-code, the barfeeder deems all these other M-codes as EOB M-codes.
Chapter 4 – Operation 4.10.2.12 #004 – REMNANT EJECTING MODE Parameter #004 influences the way of ejecting the bar remnant into the lathe workspace. #004 Control ON Control OFF ML-565/580T/S Description In this case the rest of bar can be ejected in the following ways: • The lathe tool head departs to a sufficient distance from the remnant of the bar, the lathe opens the clamping device and sends an M-code.
Chapter 4 – Operation By New Bar (S) The remnant of the bar is not ejected by the pusher; instead it is ejected by a new bar. This reduces the time needed for loading of the new bar. If this mode is selected, the bar replacement will take place as follows: 1. After the last feeding (end of bar reached) the barfeeder moves the pusher to the back limit position, lifts it up, and load a new bar from the magazine to the channel. In this position it waits for the remnant ejection command. 2.
Chapter 4 – Operation 4.10.2.13 #200 – CHANNEL POSITION The barfeeder loads bars from the magazine into the lathe as follows: First of all, it moves the stoppers (splitters) to such position that just one bar will be in the space above the channel. After it, the channel begins movement from down to up. During this movement, one bar is loaded from the magazine into the channel. Then, the channel moves to such upper position that the bar axis in the channel coincides with the axis of the lathe spindle.
Chapter 4 – Operation 4.10.2.13.
Chapter 4 – Operation 4.10.2.13.
Chapter 4 – Operation 4.10.2.14 #400 – JOBS TABLE Operator parameters together with the current bar number are technological parameters of the barfeeder. The technological parameters shall always correspond to the job performed on the lathe. At change of the job it is usually necessary to change at least some of the technological parameters. If a job is frequently repeated, you can save the values of technological parameters of the job and download them when they are required.
Chapter 4 – Operation 4.10.2.14.1 Identical job The identical job field displays the number of the first found job, which content is identical to the content of technological parameters in the memory of the barfeeder. Using the identical job you can determine whether the given combination of parameters is already saved in the Jobs Table. Identical job 000 001 to 250 Meaning The content of the parameters in the memory is not saved in the Jobs Table.
Chapter 4 – Operation 4.10.3 SERVICE PARAMETERS Service parameters are parameters which do not relate to the method of part making in the lathe. These parameters influence the timing of the interface signals, user interface and other important features of the barfeeder. Common user should not change the service parameter settings.
Chapter 4 – Operation 4.10.3.1.2 AUTOMATIC MODE SIMULATION Simulation mode is used for the testing of the newly installed barfeeder at the lathe without the need of feeding an actual bar. By the simulation it is possible to test mutual compatibility of the barfeeder and lathe interfaces. In this mode the barfeeder responds to the commands from the lathe in the same way as in the normal automatic mode, while respecting all settings of the interface in the service parameters.
Chapter 4 – Operation 4.10.3.1.3 TEST MODE The Test mode is particularly used for the barfeeder running-in. After start of this mode the barfeeder moves the pusher to the position saved in the parameter #102. After it, it returns, moves the channel to the upper position, see #200, shifts the flag into the front position, returns the flag, moves the channel to the lower limit position, and repeats the whole cycle.
Chapter 4 – Operation 4.10.3.3 #002 – END OF BAR TIMING Parameter #002 sets forth the method of sending the End of Bar signal to the lathe if there is a short bar in the lathe. #002 Short Long Mazak Standard Double Description End of Bar is only sent, if the clamping device is closed. This timing is the most frequently used timing of the End of Bar signal. End of Bar is sent to the lathe as soon as the barfeeder detects a short bar in the lathe.
Chapter 4 – Operation 4.10.3.5 #006 – LANGUAGE Parameter #006 sets the language of the barfeeder user interface. Change of the parameter #006 is implemented immediately. #006 English only at this time 4.10.3.6 #007 – K4 RELAY Parameter #007 sets the meaning of the reserve relay of the K4 interface. #007 OFF TopCutInterlock 4.10.2.3-40 Description K4 relay is inactive permanently.
Chapter 4 – Operation 4.10.3.7 #008 – M-CODE STYLE Parameter #008 sets for the method of signing the M-code off. #008 Dynamic Static Description Dynamic M-code is such M-code, which can be deactivated by the lathe independently of the barfeeder. If Dynamic M-code is set in the barfeeder, the barfeeder always after the end of the activity which started on M-code, sends the M-code end signal long 0.5 s to the lathe.
Chapter 4 – Operation 4.10.3.9 #108 – MATERIAL SWITCH POSITION (S) Parameter #108 states the distance of the material switch B34 from the barfeeder reference point. Usual value of the parameter #108 Approx. 1682 mm Use the material switch calibration function for precise setting of the parameter #108, see Chapter 4.9.5.4. 4.10.3.10 #104 – GLOBAL CHANNEL OFFSET Parameter #104 sets the offset of the Channel Position Table in relation to the position of the reference switch of the loading mechanism B31.
Chapter 4 – Operation 4.10.3.11 #109 – GLOBAL SPLITTER OFFSET Parameter #109 sets the offset of the Splitter Position in relation to the position of the loading mechanism reference switch B30. After handling the loading mechanism reference switch B30 it will be probably necessary to make a correction of the parameter #109. If the correction of the parameter #109 is not made, it can result in the loading mechanism inability to load just one bar of given size. 4.10.3.
Chapter 4 – Operation 4.10.3.13 #009 – FACTORY RESET Using the parameter #009, you can call the function that resets all important parameters, software options and other information saved in the memory of the barfeeder. This function is used in production for initial setting of all important values. Be especially careful in eventual use of the reset function.
Chapter 4 – Operation Parameters Reset function saves initial values into all operator and service parameters. It sets the bar no. 4 as the current bar in the Channel Position Table. It also resets the function evaluating successful and failed go to reference. In move to reference you will have to move the reference point. Finally, it restarts the barfeeder's PLC.
Chapter 4 – Operation Channel Positions Jobs Table Counters All & Options 4.10.2.3-46 Reset function sets initial values in the Channel Position table. Thus it overwrites the channel and stopper positions corresponding to individual bar numbers as well as the bar names (sizes) and sections. Finally, it restarts the barfeeder's PLC. Reset function deletes all values in the Jobs Table and marks all jobs as unused. Finally, it restarts the barfeeder's PLC.
Chapter 4 – Operation 4.11 HOW TO PROGRAM A LATHE WITH THE BARFEEDER There are many ways of programming a lathe with the ML barfeeder. Generally, the End of Bar test should be in the program before feeding to ensure that an arbitrarily long bar can be clamped in the lathe at start of the automatic cycle. 4.11.1 FEEDING TO STOPPER If end of bar is not reached, the barfeeder moves the bar to the stopper in the tool head. The arrival at the end of bar initiates the bar replacement subprogram.
Chapter 4 – Operation 4.11.2 FEEDING TO POSITION (S) If end of bar is not reached, the barfeeder moves the bar by a pre-programmed feeding length. The end of bar initiates the bar replacement subprogram. Main program (feeding) 1. Tool head departure to safe position 2. Spindle stop 3. End of Bar test (at end of bar the jump to subprogram for new bar loading) 4. Clamping device opening 5. M-code (the barfeeder moves the bar see #105, #106) 6. Clamping device closing (the barfeeder returns) 7.
Chapter 4 – Operation ML SERIES DIRECT CONNECT INSTRUCTIONS The ML Series Barfeeds are capable of RS232 communications, allowing certain Parameters to be altered from the Host CNC machine. This allows the Programmer to feed material for one job, and without interruption, change parameters to allow feeding for a different length part for the remaining material. The host machines macro, and RS232 communication capabilities will sometimes limit the ability to address all issues.
Chapter 4 – Operation TYPICAL FANUC MACRO PROGRAM O9014(G180 BARFEED DATA INPUT) IF[#1EQ#0]GOTO3001 IF[#2EQ#0]GOTO3002 IF[#3EQ#0]GOTO3003 IF[#7EQ#0]GOTO3004 IF[#9EQ#0]GOTO3005 IF[#11EQ#0]GOTO3006 POPEN DPRNT[ZIWRK#1[11]X] (work mode - barfeed, magazine, parts stop. var# "A") DPRNT[ZIPMD#2[11]X] (pusher mode - position, turret. var# "B") DPRNT[ZIBAR#3[34]X] (bar diameter. var#"C") DPRNT[ZIFLO#7[34]X] (feeding length odd, 1st. var"D") DPRNT[ZINBF#9[34]X] (new bar face position.
Chapter 4 – Operation 4.11.3 PARAMETER SETTING EXAMPLE Task: Produce a part long 15 mm from the bar ∅ 50 mm. Allowance for bar squaring after feeding is 0.3 mm, the width of the cut-off tool is 3 mm. Minimum clamping length is 30 mm. Let us suppose that cutting off will take place 10 mm in front of the clamping device. As bar ends are of bad quality (curved), we will first cut off the new bar face by 1.5 mm.
Chapter 4 – Operation Barfeeder feeding to position (S) Parameter Value Note #100 48.3 mm 48.3 = 15 + 3 + 0.3 + 30 #101 ??? Depends on the pusher sag. #300 50 % --#010 Position --#105 18.3 mm 18.3 = 15 + 3 + 0.3 #106 0 mm --#107 11.5 mm 11.5 = 10 + 1.5 #011 Barfeeder --#110 0 mm It is not used, see #011 #102 ??? Specific distance to the clamping device face. #301 1s Usual value. #003 Stand Still --#004 Control OFF --- 4.10.2.
Chapter 4 – Operation Feeding by the 2nd spindle of the lathe; new bar loading to stopper Parameter Value Note #100 48.3 mm 48.3 = 15 + 3 + 0.3 + 30 #101 ??? Depends on the pusher sag. #300 50 % --#010 Stopper --(1) #105 18.3 mm 18.3 = 15 + 3 + 0.3 #106 0 mm --(1) #107 0 mm S; the parameter is not used. #011 Magazine Only --#110 0 mm It is not used, see #011 #102 ??? Specific distance to the clamping device face. #301 1s Usual value.
Chapter 4 – Operation Feeding by the 2nd spindle of the lathe; new bar loading to position (S) Parameter Value Note #100 48.3 mm 48.3 = 15 + 3 + 0.3 + 30 #101 ??? Depends on the pusher sag. #300 50 % --#010 Position --(2) #105 18.3 mm 18.3 = 15 + 3 + 0.3 #106 0 mm --#107 11.5 mm 11.5 = 10 + 1.5 #011 Magazine Only --#110 0 mm It is not used, see #011 #102 ??? Specific distance to the clamping device face. #301 1s Usual value.
Chapter 4 – Operation 4.11.4 WIZARD PROGRAMMING Programming the WIZARD in with push to turret function Input Bar diameter and then press the arrow to move to the next function. down Input Feeding Length which is: Part Length + Cut off tool + space to cut off part then press the down arrow to move to the next function. The END OF BAR is automatically calculated depending on BAR DIAMETER.
Chapter 5 - Maintenance 5 MAINTENANCE 5.1 ROUTINE MAINTENANCE Weekly Remove any dirt from the barfeeder. Monthly 11 Clean the profile, guide bars and guide rollers. Grease the guide bars with grease LV2. 12 Lubricate the bearings of the pusher tilting and of the loading mechanism with machine oil. 13 Clean and oil the pusher lock bar and pin. 12 11 13 21 12 23 24 22 Fig. 5.1 Routine Maintenance Every two months 21 Check the tightening of the toothed belt of the horizontal unit.
Chapter 5 - Maintenance 5.2 ERROR MESSAGES If the barfeeder evaluates certain situation as an error status, an error message is displayed on the control panel. Cancel the error by the or key. Error Message Cause Corrective Action 1 Motor (M25) Motor power was disrupted by Estop, switching to Auto with cover open or opening cover during cycle Check all E-stop buttons on both the lathe and barfeeder. Ensure that no E-stop is on the lathe.
Chapter 5 - Maintenance Error Message Cause Corrective Action 12 Barfeed not in AUTO Mode F1 key is not in AUT position during active automatic mode of the barfeeder. If automatic mode is active, do not press other “F” function keys 15 Material (B34) At start of pushing a new bar in the spindle or at start or calibration of the switch B34, the switch must be active (its diaphragm must be in standstill position). Check the function of the material switch B34.
Chapter 5 - Maintenance Error Cause Corrective Action 41 Bar Too Short During reload check by B34, found bar to short to load. Check bar size, should be 2.5 X gap between lathe and barfeed 42 Lathe in E-Stop Lathe is in E-Stop condition Check and clear E-stop condition on lathe.
Chapter 5 - Maintenance Error Cause Corrective Action 61 Cover Is Open Access cover is open and can only run in Manual Mode Close Cover to run in AUTO Mode 62 Collet Is Not Closed During initialization cycle the PLC detect ed that the clamp device is not closed Close clamping device and restart Auto initialization.
Chapter 5 - Maintenance 5.3 ARRANGEMENT AND PURPOSE OF SWITCHES B34 SQ32 B30 SQ23 M2+E2 M1+E1 B35 B33 M3+E3 B31 Fig. 5.2 Electric Element Layout Switch SQ23 Name Cover switch B30 Stoppers in basic position Loader down B31 SQ32 (CE) Magazine closed B33 B34 (S) B35 (option) Flag back Material not present 5-6 Barfeeder position OK Description If the key S3 is in AUT position, the switch SQ23 switches off the safety relay K1, thus causing emergency stop of the barfeeder.
Chapter 5 - Maintenance 5.3.1 INTERFACE DESCRIPTION You can find the diagram of standard interface connection in 5.3.2. Barfeeder power supply Single-cable interface Twin-cable interface X1/1, X1/2, X1/PE X2/1, X2/2, X2/PE Signals from the lathe to the barfeeder The signals from the lathe to the barfeeder should be implemented by contacts of relays or switches on the lathe side. The signals are supplied with 24 VDC from the barfeeder (X1/14).
Chapter 5 - Maintenance Signals from the barfeeder to the lathe The signals from the barfeeder to the lathe are implemented by relay contacts in the barfeeder. The signals should be supplied with 24 VDC from the lathe (X1/19). Name Barfeeder E-stop Barfeeder OK Interface X1/6-X1/7 X1/8-X1/9 X1/20 K4 X1/24 End of Bar (EOB) X1/21 Revolution enabled X1/23 End of M-code (M-fin) X1/22 5.3.
Chapter 5 - Maintenance ML-565/580T/S 5.3.
Chapter 5 - Maintenance INPUT DECRIPTION SIGNALS I/O LED OUTPUT SIGNALS DECRIPTION B30 Splitter Home Position (M15) K11 Loader in Load Direction B31 Channel Home position (M11) K12 Loader active SQ32 Magazine Cover Closed (M12) K16 M3 Motor Active B33 Flag/Pusher Home Position(M120) K02 Barfeed OK B34 Bar Measurement Switch (M122) K04 Not used B35 Barfeed In Position switch (M14) K05 End of Bar S2 Manual Mode (M16=0) K06 Spindle Enable S3 Auto Mode (M16=1) K07 M-cod
Chapter 5 - Maintenance 5.3.2 ML CONTROL DIAGRAMS ML-565/580T/S 5.3.
Chapter 5 - Maintenance 5.3.
Chapter 5 - Maintenance ML-565/580T/S 5.3.
Chapter 5 - Maintenance Connect slide inpostion switch to M14 and +24G 5.3.
Chapter 5 - Maintenance Connect slide inpostion switch to M14 and +24G ML-565/580T/S 5.3.
Chapter 5 - Maintenance 0020 5.3.
Chapter 5 - Maintenance ML-565/580T/S 5.3.
Chapter 5 - Maintenance 5.3.
Chapter 5 - Maintenance ML-565/580T/S 5.3.
Chapter 5 - Maintenance 5.3.
Chapter 5 - Maintenance ML-565/580T/S 5.3.
Chapter 5 - Maintenance 5.3.
Chapter 5 - Maintenance ML-565/580T/S 5.3.
Chapter 5 - Maintenance Barfeed Control Power Supply Structure z Power Supply Structure Block Diagram 1.1.1.1.1.1 1.1.1.1.1.2 AC Tr an f MT0218 TB1.1 TB1,2 TB2.1 (DC24V) TB2.
Chapter 5 - Maintenance The connector locations are shown in the following pictures. AC200V MT0216 Power Power Supply DC +5/+12/-12/// 24V DC The MT0216 CN2 is connected to control unit bottom layer (MT0190C) CN6. All the DC powers on top layer (MT0195C) terminal strips come from bottom layer. z M2/M3 Power Supply (+26VDC) Description The M2/M3 power connected from transformer 20VAC and goes to MT0218 TB1.1 and TB1.2. This AC power rectified in MT0218 and get DC 26V to supply M2 and M3.
Chapter 5 - Maintenance 5.4 PARTS B34 SQ32 B30 SQ23 M2+E2 M1+E1 B35 B33 M3+E3 B31 QSI Handheld ML-565/580T/S 5.
Chapter 5 - Maintenance ELEMENT A A B30; B31; B33; B34; B35 ATS # 45200500 452000500-1 452000500-2 45201730 45201731 G1 G2 K1 K2; K4; K5; K6; K7 K10; K11; K12; K14; K16 45200501 M1+E1 (ML-565) 45140050 M1+E1 (ML-580,5102) M2+E2; M3+E3 S1 45160090 45120014 45130025 SM1 SQ23 SQ32 PD6 PD10 PD18 PLASTIC GEAR LEXAN COVER LEFT SIDE PANEL RIGHT SIDE PANEL FLYWHEEL GEAR, PUSHER MOTOR QSI HANDHELD HANDLE (“S” MODEL) RETRACT ELECTRICAL KIT X-AXIS SLIDE ASSY.
FORM ATS Systems Subject: All Electric Barfeed Installation and Customer Training Checklist Doc. No. FM 09-115 Rev.
FORM ATS Systems Subject: All Electric Barfeed Installation and Customer Training Checklist Doc. No. FM 09-115 Rev. E ATS Systems’ All Electric Barfeed Installation & Customer Training Checklist – Models ML565, 580 & 5102 General Inventory Checklist (See BOM for details of this specific order): ___ Interface Cables ___ SFT ___ Control software (Ver. ________) ___ Pusher ___ Handheld sftwr.
ATS Systems Subject: All Electric Barfeed Installation and Customer Training Checklist FORM Doc. No. FM 09-115 Rev. E Interface and Safety Test Checklist: Verify voltage and logic change at inputs. Activating any E-stop stops all systems. Verify that barfeed E-stop also stops lathe. Verify that lathe E-stop also stops barfeed. Opening and closing the work holding changes logic C. OPEN (See: Panel mode status bar “Ch”) Clamping device logic inverse Parameter #005.
FORM ATS Systems Subject: All Electric Barfeed Installation and Customer Training Checklist Doc. No. FM 09-115 Rev. E Training Checklist: Customer Employees Trained Include: ________________________ ________________________ _________________________ ________________________ ________________________ _________________________ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ Checking the alignment of the barfeeder and lathe.
ATS Systems Subject: All Electric Barfeed Installation and Customer Training Checklist FORM Doc. No. FM 09-115 Rev. E Extra training required for specific lathe brands: Note: Lathe builders are constantly improving their barfeed interfaces. The following is valid as of the printing of this document. Referring to the "Interface and Safety Test Checklist" section of this document, for some lathe brands you will not be able to sign off all boxes.
ATS Systems Subject: All Electric Barfeed Installation and Customer Training Checklist FORM Doc. No. FM 09-115 Rev. E ATS Systems’ Service Engineer will note here all deviations from standard recommended interface and the special training given due to the deviation.
ATS Systems Subject: All Electric Barfeed Installation and Customer Training Checklist FORM Doc. No. FM 09-115 Rev. E Re: Safe installation and operation of ATS Systems’ short magazine barfeed ATS Systems' standard policy is to install the barfeed with a maximum 2" gap between the front of the barfeed and the lathe's sheetmetal guards. A larger gap, if left unguarded, can be a safety hazard in some cases depending on the application. 1.
